A conveyor belt is a device used to transport items, made of ribbon material. It moves along the axis of the drum or drive to transport materials from one location to another, and is widely used in logistics, mining, construction, food processing and other fields. Through the conveyor belt, it can achieve continuous automatic conveying of materials, improve production efficiency, reduce labor costs and ensure the safety and stability of the production process. However, it may encounter some problems that cause interruption of operation. Here are some common conveyor belt problems and their solutions, overcome conveyor belt problems with these essential solutions which guarantee smooth operation.
Belt Mistracking
Conveyor belt deviation refers to the center line of the conveyor belt is inconsistent with the center line of the conveyor during operation, and it is biased to one side, which is one of the most common faults. The main reasons are:
- Low Installation Accuracy
- Poor Quality Conveyor Belt
- Delayed Daily Maintenance
Carefully analyze the causes of deviation and adopt the corresponding solutions:
- For the installation accuracy is low, reinstall it, pay attention to the same center line between the head and tail rollers and the middle rollers as far as possible, and parallel to each other to ensure that the conveyor belt is not biased or less biased.
- Conveyor belt quality problems, to replace as soon as possible, choose a reliable and stable conveyor belt which can reduce the downtime. Puteken has 10 years of experience in the conveyor belt industry as a reliable conveyor belt China manufacturer.
- Check the position of the material on the conveyor belt. The material is not centered on the cross section of the conveyor belt, which will cause the conveyor belt to run off. If the material goes to the right, the belt goes to the left and vice versa. During operation, the material should be centered as much as possible. In order to reduce or avoid such conveyor belt deviation, the baffle can be added to change the direction and position of the material.
- Routine maintenance:1. Re-adjust the brake device of the conveyor belt to ensure that the conveyor belt will not deviate from the track during operation. 2. Check the alignment of the conveyor belt to ensure that the conveyor belt is not disturbed by external forces during operation. 3. Install an anti-deviation device to avoid the aggravation of the fault due to the failure of finding the conveyor belt deviation in time. 4. Adjust tension to ensure proper tension. Too loose or too tight will lead to deviation.
There are many factors affecting conveyor belt deviation. At the same time, due to the different types of belt conveyors, the methods of correcting deviation are also different. The deviation phenomenon should be analyzed carefully and corresponding measures should be taken timely.
Belt Slippage
During operation of the conveyor belt, the reasons for slippage also are many, to overcome the skid phenomenon of the conveyor belt, we must first find the cause of skid, in order to take effective measures.
- The main reason for the slippage of conveyor belt is the decrease of tension force and the insufficient friction of conveyor belt on the driving drum, resulting in the slip of conveyor belt.The solution is as follows: When the conveyor belt is slipping, the tension stroke can be adjusted to increase the tension force. According to the type of conveyor belt, the tightening method is not the same. Common tensioning methods include spiral tensioning, hydraulic tensioning, steady car tensioning and weight tensioning. A belt conveyor using a weight tensioning device can be solved by adding a counterweight when the belt is slipping, adding until the belt is not slipping. If there is a permanent deformation of the conveyor belt, when the tension stroke is not enough, the conveyor belt can be cut off. However, do not blindly increase the tension, avoiding make the conveyor belt bear unnecessary excessive tension and reduce the service life of the conveyor belt. The tension of the conveyor belt should be adjusted according to the flow rate of the conveyor belt, as long as it can be pulled, do not slip and bottom conveyor belt should not wrinkle.
- The friction between the driving drum and the conveyor belt is not enough to cause slip. Most of the reason is that there are water on the conveyor belt. The solution is to add some ground rosin to the roller. However, be careful not to use the hand to add, use blast equipment to blow into, so as to avoid personal accidents. Regularly clean the surface of the drum can reduce the skid phenomenon.
- The tail or upper and lower roller bearing damage. The cause of the damage is that the tail has too much floating dust, not timely maintenance and replacement of damaged or inflexible parts, so that the increasing resistance resulting in slippage.
- Starting too fast can also result in skid. You can start slowly at this time. If the squirrel cage motor is used, it can be clicked twice and then started, which can also effectively overcome the skid phenomenon.
- The conveyor belt load is too large, more than the motor capacity will also cause slip.The advantage of slipping is to protect the motor, otherwise the motor will be burned for a long time. But for the operation, it is a skid accident.
Wear
Conveyor belts are prematurely damaged by wear, cutting or impact by following situation:
- Material wear: When handling highly corrosive materials, the surface or edge of the conveyor belt is strong worn.
- Improper installation: Improper installation of rollers or racks may cause friction between the conveyor belt and other parts of the conveyor.
- Improper operation: Improper position of materials leads to the concentration of materials in a certain area of the conveyor belt, causing partial wear.
Solution:
- Select wear resistant conveyor belt: When handling high wear materials, choose wear resistant conveyor belt, such as polyurethane, Teflon or silicone coated conveyor belts.
- Optimize equipment installation: Ensure that rollers, racks and other equipment are correctly installed to avoid abnormal friction between the conveyor belt and other parts.
- Adjust the material dropping mode: Optimize the material dropping position to ensure that the material is evenly distributed on the conveyor belt to avoid partial wear.
- Use scraper and cleaner: Install scraper and cleaner to remove debris.
- Buffering machine: Use a buffering machine to absorb shock and reduce belt damage.
Tear
The common cause of conveyor belt fracture is insufficient belt hardness or excessive operating load, the solution is as follows:
- Check whether the conveyor belt hardness meets the requirements, if no, it should be replaced immediately.
- Properly reducing the load of the conveyor belt can reduce the risk of fracture.
- Strengthen the daily maintenance of the conveyor belt, increase the service life, to avoid fracture phenomenon.
Furthermore, sharp objects in the handling material or on the surface of the conveyor belt, resulting in scratches or tears on the conveyor belt. Clean the surface of the conveyor belt regularly, clean sharp objects on the conveyor belt in time to avoid damage to the conveyor belt.
Material Scattering
The material scattering of conveyor belts is a common problem, and there are many reasons. But the key is to strengthen the daily care and maintenance.
- Material scattering at the transfer point: Scattering at the transfer point is mainly in the hopper, guide trough, etc. If the conveyor belt is seriously overloaded, the rubber skirt plate of the conveyor is damaged, and the steel plate at the guide groove is designed far away from the conveyor belt while the rubber skirt plate is longer, so that the material is rushed out of the guide groove. The above situation can be solved by controlling transport capacity and strengthening maintenance.
- Scattering when the concave conveyor belt is suspended: When the curvature radius of the concave conveyor belt is small, the conveyor belt will be suspended. At this time, the grooving situation of the conveyor belt will change, because the conveyor belt has left the groove idler set, the general groove angle becomes smaller, so that part of the material will be scattered. Therefore, in the design stage, a large concave curvature radius should be adopted as far as possible to avoid such cases. For example, in order to shorten the tail car on the mobile mechanical loading machine, stacker and reclaimer equipment, the concave section is designed as a non-arc transition interval, and it is easier to sprinkle when the conveyor belt width is small.
- Scattering when the conveyor belt mistracking: When conveyor belt mistrack, the height of the two edges of conveyor belt change during operation, one side is high, and the other side is low, and the material is scattered from the low side. The solution is to adjust the deviation of the conveyor belt.
- Too fast conveying speed: The conveyor belt runs too fast, resulting in the material can not maintain stability and easy to scatter. Adjust the conveying speed: according to the characteristics of the belt material and the conveying distance, adjust the running speed of the conveyor belt to ensure that the material can be stably transported.
- Improper material delivery: the material is not evenly distributed on the conveyor belt, resulting in overload on one side and scattering. Optimize the material delivery method and ensure that the material is evenly distributed on the conveyor belt to avoid overload on one side.
- Install baffle plates or material guide troughs: Install baffle plates or material guide troughs on both sides of the conveyor belt to prevent materials from scattering.
Excessive Noise
Reason analysis:
- Loose or worn parts: Abnormal noise will be generated when rollers, bearings and other parts of the conveyor belt are loose or worn during operation.
- Poor lubrication: Lack of lubrication system of rolling parts, resulting in increased friction and noise.
- Installation problem: Improper installation may cause friction or collision between components and make noise.
Solution:
- Check and fasten parts: Periodically check key parts such as rollers and bearings of the conveyor belt to ensure that all bolts and connectors are fastened properly.
- Lubrication of moving parts: regularly use lubricating pump add the oil to rollers, rollers and other parts to reduce friction and noise.
- Replace damaged parts: If the parts are found to be severely worn or damaged, replace them in time to prevent further damage.
Return Charge
Material sticks to the belts and is brought back, causing buildup and maintenance issues.
Solution:
- Belt cleaners: Install primary and secondary belt cleaners.
- Water spray: Use water spray to clean the conveyor belts.
- Regular maintenance: Regular maintenance to remove returned materials.
Misalignment
Poor alignment of conveyor structure, resulting in uneven wear and potential damage.
Solution:
- Periodic inspection: Periodic inspection to ensure that the conveyor structure is aligned.
- Frame adjustment: Adjust the conveyor frame and rollers to correct poor alignment.
- Structural support: Ensure adequate structural support to prevent sagging.
Temperature Influence
Extreme temperatures affect conveyor belt performance.
Solution:
- Tropical resistance: Use belts designed to withstand high temperatures.
- Cooling system: Implement a cooling system to protect the belt from high temperatures.
- Regular inspection: Monitor belts for signs of temperature-related damage.
Through the detailed understanding of common conveyor belt problems and solutions, so we can be effectively extended the overall efficiency of the conveyor system. Regular maintenance, proper selection of belts and following manufacturer’s guidelines are critical to solving conveyor belt problems. Implementing preventive measures and resolving problems timely ensures efficient and uninterrupted operation of the conveying system.
